Controller for a motor and a method of controlling the motor

ABSTRACT

A pumping apparatus for a jetted-fluid system includes a pump having an inlet connectable to the drain, and an outlet connectable to the return. The pump is adapted to receive the fluid from the drain and jet fluid through the return. The pumping apparatus includes a motor coupled to the pump to operate the pump, a sensor connectable to the power source and configured to generate a signal having a relation to a parameter of the motor, and a switch coupled to the motor and configured to control at least a characteristic of the motor. The pumping apparatus also includes a microcontroller coupled to the sensor and the switch. The microcontroller is configured to generate a derivative value based on the signal, and to control the motor based on the derivative value.

BACKGROUND

The invention relates to a controller for a motor, and particularly, acontroller for a motor operating a pump.

Occasionally on a swimming pool, spa, or similar jetted-fluidapplication, the main drain can become obstructed with an object, suchas a towel or pool toy. When this happens, the suction force of the pumpis applied to the obstruction and the object sticks to the drain. Thisis called suction entrapment. If the object substantially covers thedrain (such as a towel covering the drain), water is pumped out of thedrain side of the pump. Eventually the pump runs dry, the seals burnout, and the pump can be damaged.

Another type of entrapment is referred to as mechanical entrapment.Mechanical entrapment occurs when an object, such as a towel or pooltoy, gets tangled in the drain cover. Mechanical entrapment may alsoeffect the operation of the pump.

Several solutions have been proposed for suction and mechanicalentrapment. For example, new pool construction is required to have twodrains, so that if one drain becomes plugged, the other can still flowfreely and no vacuum entrapment can take place. This does not helpexisting pools, however, as adding a second drain to an in-ground,one-drain pool is very difficult and expensive. Modern pool drain coversare also designed such that items cannot become entwined with the cover.

As another example, several manufacturers offer systems known as SafetyVacuum Release Systems (SVRS). SVRS often contain several layers ofprotection to help prevent both mechanical and suction entrapment. MostSVRS use hydraulic release valves that are plumbed into the suction sideof the pump. The valve is designed to release (open to the atmosphere)if the vacuum (or pressure) inside the drain pipe exceeds a setthreshold, thus releasing the obstruction. These valves can be veryeffective at releasing the suction developed under these circumstances.Unfortunately, they have several technical problems that have limitedtheir use.

SUMMARY

In one embodiment, the invention provides a pumping apparatus for ajetted-fluid system having a vessel for holding a fluid, a drain, and areturn. The pumping apparatus is connected to a power source andincludes a pump having an inlet connectable to the drain, and an outletconnectable to the return. The pump is adapted to receive the fluid fromthe drain and jet fluid through the return. The pumping apparatus alsoincludes a motor coupled to the pump to operate the pump, a sensorconnectable to the power source and configured to generate a signalhaving a relation to a parameter of the motor, and a switch coupled tothe motor and configured to control at least a characteristic of themotor. The pumping apparatus also includes a microcontroller coupled tothe sensor and the switch. The microcontroller is configured to generatea derivative value based on the signal, and to control the motor basedon the derivative value.

In another embodiment, the invention provides a pumping apparatus for ajetted-fluid system having a vessel for holding a fluid, a drain, and areturn. The pumping apparatus is connected to a power source andincludes a pump including an inlet connectable to the drain, and anoutlet connectable to the return. The pump is adapted to receive thefluid from the drain and jet fluid through the return. The pumpingapparatus also includes a motor coupled to the pump to operate the pump,a sensor coupled to the motor and configured to generate a signal havinga relation to a power of the motor, and a switch coupled to the motorand configured to control at least a characteristic of the motor. Thepumping apparatus also includes a microcontroller coupled to the sensorand the relay circuit. The microcontroller is configured to generate aderivative value of a parameter based on the signal, and to control themotor based on the derivative value.

In another embodiment, the invention provides a method of controlling amotor operating a pumping apparatus of a fluid-pumping application. Thepumping apparatus includes a pump having an inlet to receive a fluid andan outlet to exhaust the fluid, and the motor is coupled to the pump tooperate the pump. The method includes sensing a motor current, sensing amotor voltage, and obtaining a derivative value of the motor power basedon the sensed voltage and the sensed current. The method also includesdetermining whether the derivative value indicates a condition of thepump, and controlling the motor to operate the pump based on thecondition of the pump.

In another embodiment, the invention provides a pumping apparatus for ajetted-fluid system comprising a vessel for holding a fluid, a drain,and a return. The pumping apparatus is connected to a power source andincludes a pump having an inlet connectable to the drain, and an outletconnectable to the return. The pump is adapted to receive the fluid fromthe drain and jet fluid through the return. The pumping apparatus alsoincludes a motor coupled to the pump to operate the pump, a sensorconnectable to the power source and configured to generate a signalhaving a relation to a parameter of the motor, and a switch coupled tothe motor and configured to control at least a characteristic of themotor. The pumping apparatus also includes a derivative device coupledto the sensor and the switch. The derivative device is configured togenerate a derivative value based on the signal to control the motorbased on the derivative value.

In another embodiment, the invention provides a pumping apparatus for ajetted-fluid system having a vessel for holding a fluid, a drain, and areturn. The pumping apparatus is connected to a power source andincludes a pump comprising an inlet connectable to the drain, and anoutlet connectable to the return. The pump is adapted to receive thefluid from the drain and jet fluid through the return. The pumpingapparatus also includes a motor coupled to the pump to operate the pump,a sensor configured to generate a signal having a relation to aparameter of the motor, and a switch coupled to the motor and configuredto control a characteristic of the motor. The pumping apparatus alsoincludes a microcontroller coupled to the sensor and the switch. Themicrocontroller is configured to generate a value based on the signal,where the value has a relation to the motor torque, and to control themotor based on the value.

In another embodiment, the invention provides a method of controlling amotor operating a pumping apparatus of a jetted fluid system having avessel for holding a fluid, a drain, and a return. The pumping apparatusincludes a pump having an inlet connectable to the drain, and an outletconnectable to the return. The pump is adapted to receive the fluid fromthe drain and jet fluid through the return, and the motor coupled to thepump to operate the pump. The method includes controlling the motor tooperate the pump, sensing a current of the motor, and calculating atorque of the motor based on the sensed current. The method alsoincludes determining whether the torque indicates a condition of thepump, and controlling the motor to operate the pump based on thecondition of the pump.

Other features and aspects of the invention will become apparent byconsideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a jetted-spa incorporating theinvention.

FIG. 2 is a block diagram of a first controller capable of being used inthe jetted-spa shown in FIG. 1.

FIGS. 3A and 3B are electrical schematics of the first controller shownin FIG. 2.

FIG. 4 is a block diagram of a second controller capable of being usedin the jetted-spa shown in FIG. 1.

FIGS. 5A and 5B are electrical schematics of the second controller shownin FIG. 4.

FIG. 6 is a block diagram of a third controller capable of being used inthe jetted-spa shown in FIG. 1.

FIG. 7 is a graph showing an input power signal and a derivative powersignal as a function of time.

FIG. 8 is a flow diagram illustrating a model observer.

FIG. 9 is a graph showing an input power signal and a processed powersignal as a function of time.

FIG. 10 is a graph showing an average input power signal and a thresholdvalue reading as a function of time.

FIG. 11 is a graph showing characterization data and fluid pressure dataas a function of flow rate.

FIG. 12 is a chart showing a numeric relationship between input powerand torque.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass direct and indirect mountings,connections, supports, and couplings. Further, “connected” and “coupled”are not restricted to physical or mechanical connections or couplings.

FIG. 1 schematically represents a jetted-spa 100 incorporating theinvention. However, the invention is not limited to the jetted-spa 100and can be used in other jetted-fluid systems (e.g., pools, whirlpools,jetted-tubs, etc.). It is also envisioned that the invention can be usedin other applications (e.g., fluid-pumping applications).

As shown in FIG. 1, the spa 100 includes a vessel 105. As used herein,the vessel 105 is a hollow container such as a tub, pool, tank, or vatthat holds a load. The load includes a fluid, such as chlorinated water,and may include one or more occupants or items. The spa further includesa fluid-movement system 110 coupled to the vessel 105. Thefluid-movement system 110 includes a drain 115, a pumping apparatus 120having an inlet 125 coupled to the drain and an outlet 130, and a return135 coupled to the outlet 130 of the pumping apparatus 120. The pumpingapparatus 120 includes a pump 140, a motor 145 coupled to the pump 140,and a controller 150 for controlling the motor 145. For theconstructions described herein, the pump 140 is a centrifugal pump andthe motor 145 is an induction motor (e.g., capacitor-start,capacitor-run induction motor; split-phase induction motor; three-phaseinduction motor; etc.). However, the invention is not limited to thistype of pump or motor. For example, a brushless, direct current (DC)motor may be used in a different pumping application. For otherconstructions, a jetted-fluid system can include multiple drains,multiple returns, or even multiple fluid movement systems.

Referring back to FIG. 1, the vessel 105 holds a fluid. When the fluidmovement system 1 10 is active, the pump 140 causes the fluid to movefrom the drain 115, through the pump 140, and jet into the vessel 105.This pumping operation occurs when the controller 150 controllablyprovides a power to the motor 145, resulting in a mechanical movement bythe motor 145. The coupling of the motor 145 (e.g., a direct coupling oran indirect coupling via a linkage system) to the pump 140 results inthe motor 145 mechanically operating the pump 140 to move the fluid. Theoperation of the controller 150 can be via an operator interface, whichmay be as simple as an ON switch.

FIG. 2 is a block diagram of a first construction of the controller 150,and FIGS. 3A and 3B are electrical schematics of the controller 150. Asshown in FIG. 2, the controller 150 is electrically connected to a powersource 155 and the motor 145.

With reference to FIG. 2 and FIG. 3B, the controller 150 includes apower supply 160. The power supply 160 includes resistors R46 and R56;capacitors C13, C14, C16, C18, C19, and C20; diodes D10 and D11; zenerdiodes D12 and D13; power supply controller U7; regulator U6; andoptical switch U8. The power supply 160 receives power from the powersource 155 and provides the proper DC voltage (e.g., ±5 VDC and ±12 VDC)for operating the controller 150.

For the controller 150 shown in FIGS. 2 and 3A, the controller 150monitors motor input power and pump inlet side pressure to determine ifa drain obstruction has taken place. If the drain 115 or plumbing isplugged on the suction side of the pump 140, the pressure on that sideof the pump 140 increases. At the same time, because the pump 140 is nolonger pumping water, input power to the motor 145 drops. If either ofthese conditions occur, the controller 150 declares a fault, the motor145 powers down, and a fault indicator lights.

A voltage sense and average circuit 165, a current sense and averagecircuit 170, a line voltage sense circuit 175, a triac voltage sensecircuit 180, and the microcontroller 185 perform the monitoring of theinput power. One example voltage sense and average circuit 165 is shownin FIG. 3A. The voltage sense and average circuit 165 includes resistorsR34, R41, and R42; diode D9; capacitor C10; and operational amplifierU4A. The voltage sense and average circuit 165 rectifies the voltagefrom the power source 155 and then performs a DC average of therectified voltage. The DC average is then fed to the microcontroller185.

One example current sense and average circuit 170 is shown in FIG. 3A.The current sense and average circuit 170 includes transformer T1 andresistor R45, which act as a current sensor that senses the currentapplied to the motor. The current sense and average circuit alsoincludes resistors R25, R26, R27, R28, and R33; diodes D7 and D8;capacitor C9; and operational amplifiers U4C and U4D, which rectify andaverage the value representing the sensed current. For example, theresultant scaling of the current sense and average circuit 170 can be anegative five to zero volt value corresponding to a zero to twenty-fiveamp RMS value. The resulting DC average is then fed to themicrocontroller 185.

One example line voltage sense circuit 175 is shown in FIG. 3A. The linevoltage sense circuit 175 includes resistors R23, R24, and R32; diodeD5; zener diode D6; transistor Q6; and NAND gate U2B. The line voltagesense circuit 175 includes a zero-crossing detector that generates apulse signal. The pulse signal includes pulses that are generated eachtime the line voltage crosses zero volts.

One example triac voltage sense circuit 180 is shown in FIG. 3A. Thetriac voltage sense circuit 180 includes resistors R1, R5, and R6; diodeD2; zener diode D1; transistor Q1; and NAND gate U2A. The triac voltagesense circuit includes a zero-crossing detector that generates a pulsesignal. The pulse signal includes pulses that are generated each timethe motor current crosses zero.

One example microcontroller 185 that can be used with the invention is aMotorola brand microcontroller, model no. MC68HC908QY4CP. Themicrocontroller 185 includes a processor and a memory. The memoryincludes software instructions that are read, interpreted, and executedby the processor to manipulate data or signals. The memory also includesdata storage memory. The microcontroller 185 can include other circuitry(e.g., an analog-to-digital converter) necessary for operating themicrocontroller 185. In general, the microcontroller 185 receives inputs(signals or data), executes software instructions to analyze the inputs,and generates outputs (signals or data) based on the analyses. Althoughthe microcontroller 185 is shown and described, the functions of themicrocontroller 185 can be implemented with other devices, including avariety of integrated circuits (e.g., an application-specific-integratedcircuit), programmable devices, and/or discrete devices, as would beapparent to one of ordinary skill in the art. Additionally, it isenvisioned that the microcontroller 185 or similar circuitry can bedistributed among multiple microcontrollers 185 or similar circuitry. Itis also envisioned that the microcontroller 185 or similar circuitry canperform the function of some of the other circuitry described (e.g.,circuitry 165-180) above for the controller 150. For example, themicrocontroller 185, in some constructions, can receive a sensed voltageand/or sensed current and determine an averaged voltage, an averagedcurrent, the zero-crossings of the sensed voltage, and/or the zerocrossings of the sensed current.

The microcontroller 185 receives the signals representing the averagevoltage applied to the motor 145, the average current through the motor145, the zero crossings of the motor voltage, and the zero crossings ofthe motor current. Based on the zero crossings, the microcontroller 185can determine a power factor. The power factor can be calculated usingknown mathematical equations or by using a lookup table based on themathematical equations. The microcontroller 185 can then calculate apower with the averaged voltage, the averaged current, and the powerfactor as is known. As will be discussed later, the microcontroller 185compares the calculated power with a power calibration value todetermine whether a fault condition (e.g., due to an obstruction) ispresent.

Referring again to FIGS. 2 and 3A, a pressure (or vacuum) sensor circuit190 and the microcontroller 185 monitor the pump inlet side pressure.One example pressure sensor circuit 190 is shown in FIG. 3A. Thepressure sensor circuit 190 includes resistors R16, R43, R44, R47, andR48; capacitors C8, C12, C15, and C17; zener diode D4, piezoresistivesensor U9, and operational amplifier U4-B. The piezoresistive sensor U9is plumbed into the suction side of the pump 140. The pressure sensorcircuit 190 and microcontroller 185 translate and amplify the signalgenerated by the piezoresistive sensor U9 into a value representinginlet pressure. As will be discussed later, the microcontroller 185compares the resulting pressure value with a pressure calibration valueto determine whether a fault condition (e.g., due to an obstruction) ispresent.

The calibrating of the controller 150 occurs when the user activates acalibrate switch 195. One example calibrate switch 195 is shown in FIG.3A. The calibrate switch 195 includes resistor R18 and Hall effectswitch U1. When a magnet passes Hall effect switch U10, the switch 195generates a signal provided to the microcontroller 185. Upon receivingthe signal, the microcontroller 185 stores a pressure calibration valuefor the pressure sensor by acquiring the current pressure and stores apower calibration value for the motor by calculating the present power.

As stated earlier, the controller 150 controllably provides power to themotor 145. With references to FIG. 2 and 3A, the controller 150 includesa retriggerable pulse generator circuit 200. The retriggerable pulsegenerator circuit 200 includes resistor R7, capacitor C1, and pulsegenerator U1A, and outputs a value to NAND gate U2D if the retriggerablepulse generator circuit 200 receives a signal having a pulse frequencygreater than a set frequency determined by resistor R7 and capacitor C1.The NAND gate U2D also receives a signal from power-up delay circuit205, which prevents nuisance triggering of the relay on startup. Theoutput of the NAND gate U2D is provided to relay driver circuit 210. Therelay driver circuit 210 shown in FIG. 3A includes resistors R19, R20,R21, and R22; capacitor C7; diode D3; and switches Q5 and Q4. The relaydriver circuit 210 controls relay K1.

The microcontroller 185 also provides an output to triac driver circuit215, which controls triac Q2. As shown in FIG. 3A, the triac drivercircuit 215 includes resistors R12, R13, and R14; capacitor C11; andswitch Q3. In order for current to flow to the motor, relay K1 needs toclose and triac Q2 needs to be triggered on.

The controller 150 also includes a thermoswitch S1 for monitoring thetriac heat sink, a power supply monitor 220 for monitoring the voltagesproduced by the power supply 160, and a plurality of LEDs DS1, DS2, andDS3 for providing information to the user. In the construction shown, agreen LED DS1 indicates power is applied to the controller 150, a redLED DS2 indicates a fault has occurred, and a third LED DS3 is aheartbeat LED to indicate the microcontroller 185 is functioning. Ofcourse, other interfaces can be used for providing information to theoperator.

The following describes the normal sequence of events for one method ofoperation of the controller 150. When the fluid movement system 110 isinitially activated, the system 110 may have to draw air out of thesuction side plumbing and get the fluid flowing smoothly. This “priming”period usually lasts only a few seconds, but could last a minute or moreif there is a lot of air in the system. After priming, the water flow,suction side pressure, and motor input power remain relatively constant.It is during this normal running period that the circuit is effective atdetecting an abnormal event. The microcontroller 185 includes astartup-lockout feature that keeps the monitor from detecting theabnormal conditions during the priming period.

After the system 110 is running smoothly, the spa operator can calibratethe controller 150 to the current spa running conditions. Thecalibration values are stored in the microcontroller 185 memory, andwill be used as the basis for monitoring the spa 100. If for some reasonthe operating conditions of the spa change, the controller 150 can bere-calibrated by the operator. If at any time during normal operations,however, the suction side pressure increases substantially (e.g., 12%)over the pressure calibration value, or the motor input power drops(e.g., 12%) under the power calibration value, the pump will be powereddown and a fault indicator is lit.

As discussed earlier, the controller 150 measures motor input power, andnot just motor power factor or input current. Some motors haveelectrical characteristics such that power factor remains constant whilethe motor is unloaded. Other motors have an electrical characteristicsuch that current remains relatively constant when the pump is unloaded.However, the input power drops on pump systems when the drain isplugged, and water flow is impeded.

The voltage sense and average circuit 165 generates a value representingthe average power line voltage and the current sense and average circuit170 generates a value representing the average motor current. Motorpower factor is derived from the difference between power line zerocrossing events and triac zero crossing events. The line voltage sensecircuit 175 provides a signal representing the power line zerocrossings. The triac zero crossings occur at the zero crossings of themotor current. The triac voltage sense circuit 180 provides a signalrepresenting the triac zero crossings. The time difference from the zerocrossing events is used to look up the motor power factor from a tablestored in the microcontroller 185. This data is then used to calculatethe motor input power using equation e1.

V _(avg) *I _(avg) *PF=Motor_Input_Power   [e1]

The calculated motor_input_power is then compared to the calibratedvalue to determine whether a fault has occurred. If a fault hasoccurred, the motor is powered down and the fault LED DS2 is lit.

FIG. 4 is a block diagram of a second construction of the controller 150a, and FIGS. 5A and 5B are an electrical schematic of the controller 150a. As shown in FIG. 4, the controller 150 a is electrically connected toa power source 155 and the motor 145.

With reference to FIG. 4 and FIG. 5B, the controller 150 a includes apower supply 160 a. The power supply 160 a includes resistors R54, R56and R76; capacitors C16, C18, C20, C21, C22, C23 and C25; diodes D8, D10and D11; zener diodes D6, D7 and D9; power supply controller U11;regulator U9; inductors L1 and L2, surge suppressors MOV1 and MOV2, andoptical switch U10. The power supply 160 a receives power from the powersource 155 and provides the proper DC voltage (e.g., +5 VDC and +12 VDC)for operating the controller 150 a.

For the controller 150 a shown in FIG. 4, FIG. 5A, and FIG. 5B, thecontroller 150 a monitors motor input power to determine if a drainobstruction has taken place. Similar to the earlier disclosedconstruction, if the drain 115 or plumbing is plugged on the suctionside of the pump 140, the pump 140 will no longer be pumping water, andinput power to the motor 145 drops. If this condition occurs, thecontroller 150 a declares a fault, the motor 145 powers down, and afault indicator lights.

A voltage sense and average circuit 165 a, a current sense and averagecircuit 170 a, and the microcontroller 185 a perform the monitoring ofthe input power. One example voltage sense and average circuit 165 a isshown in FIG. 5A. The voltage sense and average circuit 165 a includesresistors R2, R31, R34, R35, R39, R59, R62, and R63; diodes D2 and D12;capacitor C14; and operational amplifiers U5C and U5D. The voltage senseand average circuit 165 a rectifies the voltage from the power source155 and then performs a DC average of the rectified voltage. The DCaverage is then fed to the microcontroller 185 a. The voltage sense andaverage circuit 165 a further includes resistors R22, R23, R27, R28,R30, and R36; capacitor C27; and comparator U7A; which provide the signof the voltage waveform (i.e., acts as a zero-crossing detector) to themicrocontroller 185 a.

One example current sense and average circuit 170 a is shown in FIG. 5B.The current sense and average circuit 170 a includes transformer T1 andresistor R53, which act as a current sensor that senses the currentapplied to the motor 145. The current sense and average circuit 170 aalso includes resistors R18, R20, R21, R40, R43, and R57; diodes D3 andD4; capacitor C8; and operational amplifiers U5A and U5B, which rectifyand average the value representing the sensed current. For example, theresultant scaling of the current sense and average circuit 170 a can bea positive five to zero volt value corresponding to a zero totwenty-five amp RMS value. The resulting DC average is then fed to themicrocontroller 185 a. The current sense and average circuit 170 afurther includes resistors R24, R25, R26, R29, R41, and R44; capacitorC11; and comparator U7B; which provide the sign of the current waveform(i.e., acts as a zero-crossing detector) to microcontroller 185 a.

One example microcontroller 185 a that can be used with the invention isa Motorola brand microcontroller, model no. MC68HC908QY4CP. Similar towhat was discussed for the earlier construction, the microcontroller 185a includes a processor and a memory. The memory includes softwareinstructions that are read, interpreted, and executed by the processorto manipulate data or signals. The memory also includes data storagememory. The microcontroller 185 a can include other circuitry (e.g., ananalog-to-digital converter) necessary for operating the microcontroller185 a and/or can perform the function of some of the other circuitrydescribed above for the controller 150 a. In general, themicrocontroller 185 a receives inputs (signals or data), executessoftware instructions to analyze the inputs, and generates outputs(signals or data) based on the analyses.

The microcontroller 185 a receives the signals representing the averagevoltage applied to the motor 145, the average current through the motor145, the zero crossings of the motor voltage, and the zero crossings ofthe motor current. Based on the zero crossings, the microcontroller 185a can determine a power factor and a power as was described earlier. Themicrocontroller 185 a can then compare the calculated power with a powercalibration value to determine whether a fault condition (e.g., due toan obstruction) is present.

The calibrating of the controller 150 a occurs when the user activates acalibrate switch 195 a. One example calibrate switch 195 a is shown inFIG. 5A, which is similar to the calibrate switch 195 shown in FIG. 3A.Of course, other calibrate switches are possible. In one method ofoperation for the calibrate switch 195 a, a calibration fob needs to beheld near the switch 195 a when the controller 150 a receives an initialpower. After removing the magnet and cycling power, the controller 150 agoes through priming and enters an automatic calibration mode (discussedbelow).

The controller 150 a controllably provides power to the motor 145. Withreferences to FIG. 4 and 5A, the controller 150 a includes aretriggerable pulse generator circuit 200 a. The retriggerable pulsegenerator circuit 200 a includes resistors R15 and R16, capacitors C2and C6, and pulse generators U3A and U3B, and outputs a value to therelay driver circuit 210 a if the retriggerable pulse generator circuit200 a receives a signal having a pulse frequency greater than a setfrequency determined by resistors R15 and R16, and capacitors C2 and C6.The retriggerable pulse generators U3A and U3B also receive a signalfrom power-up delay circuit 205 a, which prevents nuisance triggering ofthe relays on startup. The relay driver circuits 210 a shown in FIG. 5Ainclude resistors R1, R3, R47, and R52; diodes D1 and D5; and switchesQ1 and Q2. The relay driver circuits 210 a control relays K1 and K2. Inorder for current to flow to the motor, both relays K1 and K2 need to“close”.

The controller 150 a further includes two voltage detectors 212 a and214 a. The first voltage detector 212 a includes resistors R71, R72, andR73; capacitor C26; diode D14; and switch Q4. The first voltage detector212 a detects when voltage is present across relay K1, and verifies thatthe relays are functioning properly before allowing the motor to beenergized. The second voltage detector 214 a includes resistors R66,R69, and R70; capacitor C9; diode D13; and switch Q3. The second voltagedetector 214 a senses if a two speed motor is being operated in high orlow speed mode. The motor input power trip values are set according towhat speed the motor is being operated. It is also envisioned that thecontroller 150 a can be used with a single speed motor without thesecond voltage detector 214 a (e.g., controller 150 b is shown in FIG.6).

The controller 150 a also includes an ambient thermal sensor circuit 216a for monitoring the operating temperature of the controller 150 a, apower supply monitor 220 a for monitoring the voltages produced by thepower supply 160 a, and a plurality of LEDs DS1 and DS3 for providinginformation to the user. In the construction shown, a green LED DS2indicates power is applied to the controller 150 a, and a red LED DS3indicates a fault has occurred. Of course, other interfaces can be usedfor providing information to the operator.

The controller 150 a further includes a clean mode switch 218 a, whichincludes switch U4 and resistor R10. The clean mode switch can beactuated by an operator (e.g., a maintenance person) to deactivate thepower monitoring function described herein for a time period (e.g., 30minutes so that maintenance person can clean the vessel 105). Moreover,the red LED DS3 can be used to indicate that controller 150 a is in aclean mode. After the time period, the controller 150 a returns tonormal operation. In some constructions, the maintenance person canactuate the clean mode switch 218 a for the controller 150 a to exit theclean mode before the time period is completed.

In some cases, it may be desirable to deactivate the power monitoringfunction for reasons other than performing cleaning operations on thevessel 105. Such cases may be referred as “deactivate mode”, “disabledmode”, “unprotected mode”, or the like. Regardless of the name, thislater mode of operation can be at least partially characterized by theinstructions defined under the clean mode operation above. Moreover,when referring to the clean mode and its operation herein, thediscussion also applies to these later modes for deactivating the powermonitoring function and vice versa.

The following describes the normal sequence of events for one method ofoperation of the controller 150 a, some of which may be similar to themethod of operation of the controller 150. When the fluid movementsystem 110 is initially activated, the system 110 may have to prime(discussed above) the suction side plumbing and get the fluid flowingsmoothly (referred to as “the normal running period”). It is during thenormal running period that the circuit is most effective at detecting anabnormal event.

Upon a system power-up, the system 110 can enter a priming period. Thepriming period can be preset for a time duration (e.g., a time durationof 3 minutes), or for a time duration determined by a sensed condition.After the priming period, the system 110 enters the normal runningperiod. The controller 150 a can include instructions to perform anautomatic calibration to determine one or more calibration values aftera first system power-up. One example calibration value is a powercalibration value. In some cases, the power calibration value is anaverage of monitored power values over a predetermined period of time.The power calibration value is stored in the memory of themicrocontroller 185, and will be used as the basis for monitoring thevessel 105.

If for some reason the operating conditions of the vessel 105 change,the controller 150 a can be re-calibrated by the operator. In someconstructions, the operator actuates the calibrate switch 195 a to erasethe existing one or more calibration values stored in the memory of themicrocontroller 185. The operator then powers down the system 110,particularly the motor 145, and performs a system power-up. The system110 starts the automatic calibration process as discussed above todetermine new one or more calibration values. If at any time duringnormal operation, the monitored power varies from the power calibrationvalue (e.g., varies from a 12.5% window around the power calibrationvalue), the motor 145 will be powered down and the fault LED DS3 is lit.

In one construction, the automatic calibration instructions include notmonitoring the power of the motor 145 during a start-up period,generally preset for a time duration (e.g., 2 seconds), upon the systempower-up. In the case when the system 110 is operated for the firsttime, the system 110 enters the prime period, upon completion of thestart-up period, and the power of the motor 145 is monitored todetermine the power calibration value. As indicated above, the powercalibration value is stored in the memory of the microcontroller 185.After completion of the 3 minutes of the priming period, the system 110enters the normal running period. In subsequent system power-ups, themonitored power is compared against the power calibration value storedin the memory of the microcontroller 185 memory during the primingperiod. More specifically, the system 110 enters the normal runningperiod when the monitored power rises above the power calibration valueduring the priming period. In some cases, the monitored power does notrise above the power calibration value within the 3 minutes of thepriming period. As a consequence, the motor 145 is powered down and afault indicator is lit.

In other constructions, the priming period of the automatic calibrationcan include a longer preset time duration (for example, 4 minutes) or anadjustable time duration capability. Additionally, the controller 150 acan include instructions to perform signal conditioning operations tothe monitored power. For example, the controller 150 a can includeinstructions to perform an IIR filter to condition the monitored power.In some cases, the IIR filter can be applied to the monitored powerduring the priming period and the normal operation period. In othercases, the IIR filter can be applied to the monitored power upondetermining the power calibration value after the priming period.

Similar to controller 150, the controller 150 a measures motor inputpower, and not just motor power factor or input current. However, it isenvisioned that the controllers 150 or 150 a can be modified to monitorother motor parameters (e.g., only motor current, only motor powerfactor, or motor speed). But motor input power is the preferred motorparameter for controller 150 a for determining whether the water isimpeded. Also, it is envisioned that the controller 150 a can bemodified to monitor other parameters (e.g., suction side pressure) ofthe system 110.

For some constructions of the controller 150 a, the microcontroller 185a monitors the motor input power for an over power condition in additionto an under power condition. The monitoring of an over power conditionhelps reduce the chance that controller 150 a was incorrectlycalibrated, and/or also helps detect when the pump is over loaded (e.g.,the pump is moving too much fluid).

The voltage sense and average circuit 165 a generates a valuerepresenting the averaged power line voltage and the current sense andaverage circuit 170 a generates a value representing the averaged motorcurrent. Motor power factor is derived from the timing differencebetween the sign of the voltage signal and the sign of the currentsignal. This time difference is used to look up the motor power factorfrom a table stored in the microcontroller 185 a. The averaged powerline voltage, the averaged motor current, and the motor power factor arethen used to calculate the motor input power using equation e1 as wasdiscussed earlier. The calculated motor input power is then compared tothe calibrated value to determine whether a fault has occurred. If afault has occurred, the motor is powered down and the fault indicator islit.

Redundancy is also used for the power switches of the controller 150 a.Two relays K1 and K2 are used in series to do this function. This way, afailure of either component will still leave one switch to turn off themotor 145. As an additional safety feature, the proper operation of bothrelays is checked by the microcontroller 185 a every time the motor 145is powered-on via the relay voltage detector circuit 212 a.

Another aspect of the controller 150 a is that the microcontroller 185 aprovides pulses at a frequency greater than a set frequency (determinedby the retriggerable pulse generator circuits) to close the relays K1and K2. If the pulse generators U3A and U3B are not triggered at theproper frequency, the relays K1 and K2 open and the motor powers down.

As previously indicated, the microcontroller 185, 185 a can calculate aninput power based on parameters such as averaged voltage, averagedcurrent, and power factor. The microcontroller 185, 185 a then comparesthe calculated input power with the power calibration value to determinewhether a fault condition (e.g., due to an obstruction) is present.Other constructions can include variations of the microcontroller 185,185 a and the controller 150, 150 a operable to receive other parametersand determine whether a fault condition is present.

One aspect of the controller 150, 150 a is that the microcontroller 185,185 a can monitor the change of input power over a predetermine periodof time. More specifically, the microcontroller 185, 185 a determinesand monitors a power derivative value equating about a change in inputpower divided by a change in time. In cases where the power derivativetraverses a threshold value, the controller 150, 150 a controls themotor 145 to shut down the pump 140. This aspect of the controller 150,150 a may be operable in replacement of, or in conjunction with, othersimilar aspects of the controller 150, 150 a, such as shutting down themotor 145 when the power level of the motor 145 traverses apredetermined value.

For example, FIG. 7 shows a graph indicating input power and powerderivative as functions of time. More specifically, FIG. 7 shows a powerreading (line 300) and a power derivate value (line 305), over a30-second time period, of a motor 145 calibrated at a power thresholdvalue of 5000 and a power derivative threshold of −100. In thisparticular example, a water blockage in the fluid-movement system 110(shown in FIG. 1) occurs at the 20-second mark. It can be observed fromFIG. 7 that the power reading 300 indicates a power level drop below thethreshold value of 5000 at the 27-second mark, causing the controller150, 150 a to shut down the pump 140 approximately at the 28-secondmark. It can also be observed that the power derivative value 305 dropsbelow the −100 threshold value at the 22-second mark, causing thecontroller 150, 150 a to shut down the pump 140 approximately at the23-second mark. Other parameters of the motor 145 (e.g., torque) can bemonitored by the microcontroller 185, 185 a, for determining a potentialentrapment event.

In another aspect of the controller 150, 150 a, the microcontroller 185,185 a can include instructions that correspond to a model observer, suchas the exemplary model observer 310 shown in FIG. 8. The model observer310 includes a first filter 315, a regulator 325 having a variable gain326 and a transfer function 327, a fluid system model 330 having a gainparameter (shown in FIG. 8 with the value of 1), and a second filter335. In particular, the fluid system model 330 is configured to simulatethe fluid-movement system 110. Additionally, the first filter 315 andthe second filter 335 can include various types of analog and digitalfilters such as, but not limited to, low pass, high pass, band pass,anti-aliasing, IIR, and/or FIR filters.

It is to be understood that the model observer 310 is not limited to theelements described above. In other words, the model observer 310 may notnecessarily include all the elements described above and/or may includeother elements or combination of elements not explicitly describedherein. In reference particularly to the fluid system model 330, a fluidsystem model may be defined utilizing various procedures. In some cases,a model may be generated for this particular aspect of the controller150, 150 a from another model corresponding to a simulation of anothersystem, which may not necessarily be a fluid system. In other cases, amodel may be generated solely based on controls knowledge of closed loopor feed back systems and formulas for fluid flow and power. In yet othercases, a model may be generated by experimentation with a prototype ofthe fluid system to be modeled.

In reference to the model observer 310 of FIG. 8, the first filter 315receives a signal (P) corresponding to a parameter of the motor 145determined and monitored by the microcontroller 185, 185 a (e.g., inputpower, torque, current, power factor, etc.). Generally, the first filter315 is configured to substantially eliminate the noise in the receivedsignal (P), thus generating a filtered signal (PA). However, the firstfilter 315 may perform other functions such as anti-aliasing orfiltering the received signal to a predetermined frequency range. Thefiltered signal (PA) enters a feed-back loop 340 of the model observer310 and is processed by the regulator 325. The regulator 325 outputs aregulated signal (ro) related to the fluid flow and/or pressure throughthe fluid-movement system 110 based on the monitored parameter. Theregulated signal can be interpreted as a modeled flow rate or modeledpressure. The fluid system model 330 processes the regulated signal (ro)to generate a model signal (Fil), which is compared to the filteredsignal (PA) through the feed-back loop 340. The regulated signal (ro) isalso fed to the second filter 335 generating a control signal (roP),which is subsequently used by the microcontroller 185, 185 a to at leastcontrol the operation of the motor 145.

As shown in FIG. 8, the regulated signal (ro), indicative of fluid flowand/or pressure, is related to the monitored parameter as shown inequation [e2].

ro=(PA−Fil)*regulator   [e2]

The relationship shown in equation [e2] allows a user to control themotor 145 based on a direct relationship between the input power ortorque and a parameter of the fluid flow, such as flow rate andpressure, without having to directly measure the fluid flow parameter.

FIG. 9 is a graph showing an input power (line 345) and a processedpower or flow unit (line 350) as functions of time. More specifically,the graph of FIG. 9 illustrates the operation of the fluid-movementsystem 110 with the motor 145 having a threshold value of 5000. For thisparticular example, FIG. 9 shows that the pump inlet 125 blocked at the5-second mark. The input power drops below the threshold mark of 5000,and therefore the controller 150, 150 a shuts down the pump 140approximately at the 12.5-second mark. Alternatively, the processedpower signal drops below the threshold mark corresponding to 5000 at the6-second mark, and therefore the controller 150, 150 a shuts down thepump 140 approximately at the 7-second mark.

In this particular example, the gain parameter of the fluid system model330 is set to a value of 1, thereby measuring a unit of pressure withthe same scale as the unit of power. In other examples, the user can setthe gain parameter at a different value to at least control aspects ofthe operation of the motor 145, such as shut down time.

In another aspect of the controller 150, 150 a, the microcontroller 185,185 a can be configured for determining a floating the threshold valueor trip value indicating the parameter reading, such as input power ortorque, at which the controller 150, 150 a shuts down the pump 140. Itis to be understood that the term “floating” refers to varying oradjusting a signal or value. In one example, the microcontroller 185,185 a continuously adjusts the trip value based on average input powerreadings, as shown in FIG. 10. More specifically, FIG. 10 shows a graphindicating an average input power signal (line 355) determined andmonitored by the microcontroller 185, 185 a, a trip signal (line 360)indicating a variable trip value, and a threshold value of about 4500(shown in FIG. 10 with arrow 362) as a function of time. In thisparticular case, the threshold value 362 is a parameter indicating theminimum value that the trip value can be adjusted to.

The microcontroller 185, 185 a may calculate the average input power 355utilizing various methods. In one construction, the microcontroller 185,185 a may determine a running average based at least on signalsgenerated by the current sense and average circuit 170, 170 a andsignals generated by the voltage sense and average circuit 165, 165 a.In another construction, the microcontroller 185, 185 a may determine aninput power average over relatively short periods of time. As shown inFIG. 10, the average power determined by the microcontroller 185, 185 agoes down from about 6000 to about 5000 in a substantially progressivemanner over a time period of 80 units of time. It can also be observedthat the signal 360 indicating the trip value is adjusted down to about10% from the value at the 0-time unit mark to the 80-time unit mark andis substantially parallel to the average power 355. More specifically,the microcontroller 185, 185 a adjusts the trip value based onmonitoring the average input power 355.

In some cases, the average power signal 355 may define a behavior, suchas the one shown in FIG. 10, due to sustained clogging of thefluid-movement system 110 over a period of time, for example from the0-time unit mark to the 80-time unit mark. In other words, sustainedclogging of the fluid-movement system 110 can be determined andmonitored by the microcontroller 185, 185 a in the form of the averagepower signal 355. In these cases, the microcontroller 185, 185 a canalso determine a percentage or value indicative of a minimum averageinput power allowed to be supplied to the motor 145, or a minimumallowed threshold value such as threshold value 362. When thefluid-movement system 110 is back-flushed with the purpose of uncloggingthe fluid-movement system 110, the average power signal 355 returns tonormal unrestricted fluid flow (shown in FIG. 10 between about the84-time unit mark and about the 92-time unit mark, for example). Asshown in FIG. 10, unclogging the fluid-movement system 110 can result inrelative desired fluid flow through the fluid-movement system 110. As aconsequence, the microcontroller 185, 185 a senses an average powerchange as indicated near the 80-time unit mark in FIG. 10 showing as theaverage power returns to the calibration value.

In other cases, the microcontroller 185, 185 a can determine and monitorthe average input power over a relatively short amount of time. Forexample, the microcontroller 185, 185 a can monitor the average powerover a first time period (e.g., 5 seconds). The controller 185, 185 acan also determine a variable trip value based on a predeterminepercentage (e.g., 6.25%) drop of the average power calculated over thefirst time period. In other words, the variable trip value is adjustedbased on the predetermined percentage as the microcontroller 185, 185 adetermines the average power. The controller 150, 150 a can shut downthe pump 140 when the average power drops to a value substantially equalor lower than the variable trip value and sustains this condition over asecond period of time (e.g., 1 second).

In another aspect of the controller 150, 150 a, the microcontroller 185,185 a can be configured to determine a relationship between a parameterof the motor 145 (such as power or torque) and pressure/flow through thefluid-movement system 110 for a specific motor/pump combination. Morespecifically, the controller 150, 150 a controls the motor 145 tocalibrate the fluid-movement system 110 based on the environment inwhich the fluid-movement system 110 operates. The environment in whichthe fluid-movement system 110 operates can be defined by the capacity ofthe vessel 105, tubing configuration between the drain 115 and inlet125, tubing configuration between outlet 130 and return 135 (shown inFIG. 1), number of drains and returns, and other factors not explicitlydiscussed herein.

Calibration of the fluid-movement system 110 is generally performed thefirst time the system is operated after installation. It is to beunderstood that the processes described herein are also applicable torecalibration procedures. In one example, calibration of thefluid-movement system 110 includes determining a threshold value basedon characterizing a specific motor/pump combination and establishing arelationship between, for example, input power and pressure via a storedlook-up table or an equation. FIG. 11 shows a chart havingcharacterization data (line 365), measured in kilowatts and obtainedthrough a calibration process, and a pump curve (line 370) indicatinghead pressure. The characterization data 365 and the pump curve 370 aregraphed as a function of flow measured in gallons per minute (GPM). Inthe particular example shown in FIG. 11, it is possible for a user (orthe microcontroller 185, 185 a in an automated process) to establish atrip value based on a percent reduction in flow or pressure instead of apercent reduction in input power.

Referring particularly to the characterization data 365 shown in FIG.11, if an operating point for the fluid-movement system 110 isdetermined at point 1 on the characterization data 365, a 30% reductionin flow from 100 GPM to 70 GPM (point 2 on the characterization data365) through the fluid-movement system 110 is monitored by themicrocontroller 185, 185 a and indicates a 7% reduction in input power.For a different environment of the fluid-movement system 110, theoperating set point can be established at point 2, for example.Particularly, a 30% reduction in flow from 70 GPM to 50 GPM (point 3 onthe characterization data 365) through the fluid-movement system 110 ismonitored by the microcontroller 185, 185 a and indicates an 11%reduction in power. For the two cases described above, it is possiblethat a 30% reduction in flow is a desired operating condition, thus auser (or microcontroller 185, 185 a) can establish a trip value orpercentage based on the percent reduction (e.g., a reduction of 30% inflow) separate from the determined and monitored power.

In another aspect of the controller 150, 150 a, the microcontroller 185,185 a can include a timer function to operate the fluid-movement system110. In one example, the timer function of the microcontroller 185, 185a implements a RUN mode of the controller 150, 150 a. More specificallyregarding the RUN mode, the controller 150, 150 a is configured tooperate the motor 145 automatically over predetermined periods of time.In other words, the controller 150, 150 a is configured to control themotor 145 based on predetermined time periods programmed in themicrocontroller 185, 185 a during manufacturing or programmed by a user.In another example, the timer function of the microcontroller 185, 185 aimplements an OFF mode of the controller 150, 150 a. More specificallyregarding the OFF mode, the controller 150, 150 a is configured tooperate the motor 145 only as a result of direct interaction of theuser. In other words, the controller 150, 150 a is configured tomaintain the motor 145 off until a user directly operates the controller150, 150 a through the interface of the controller 150, 150 a. In yetanother example, the timer function of the microcontroller 185, 185 aimplements a PROGRAM mode of the controller 150, 150 a. Morespecifically regarding the PROGRAM mode, the controller 150, 150 a isconfigured to maintain the motor 145 off until the user actuates one ofthe switches (e.g., calibrate switch 195, 195 a, clean mode switch 218a) of the controller 150, 150 a indicating a desired one-time window ofoperation of the motor 145. For example, the user can actuate one switchthree times indicating the controller 150, 150 a to operate the motor145 for a period of three hours. In some constructions, the controller150, 150 a includes a run-off-program switch to operate the controller150, 150 a between the RUN, OFF, and PROGRAM modes. It is to beunderstood that the same or other modes of operation of the controller150, 150 a can be defined differently. Additionally, not all modesdescribed above are necessary and the controller 150, 150 a can includea different number and combinations of modes of operation.

In another aspect of the controller 150, 150 a, the microcontroller 185,185 a can be configured to determine and monitor a value correspondingto the torque of the motor 145. More specifically, the microcontroller185, 185 a receives signals from at least one of the voltage sense andaverage circuit 165, 165 a and the current sense and average circuit170, 170 a to help determine the torque of the motor 145. As explainedabove, the microcontroller 185, 185 a can also be configured todetermine and monitor the speed of the motor 145, allowing themicrocontroller 185, 185 a to determine a value indicative of the torqueof the motor 145 and a relationship between the torque and the inputpower. In some constructions, the speed of the motor 145 remainssubstantially constant during operation of the motor 145. In theseparticular cases, the microcontroller 185, 185 a can includeinstructions related to formulas or look-up tables that indicate adirect relationship between the input power and the torque of the motor145. Determining and monitoring the torque of the motor 145 allows themicrocontroller 185, 185 a to establish a trip value or a percentagebased on torque to shut off the motor 145 in case of an undesiredcondition of the motor 145. For example, FIG. 12 shows a chartindicating a relationship between input power and torque for a motor 145under the observation that the speed of the motor 145 changes less than2%. Thus, the microcontroller 185, 185 a can determine and monitortorque based on input power and under the assumption of constant speed.

In some constructions, the fluid-movement system 110 can operate two ormore vessels 105. For example, the fluid-movement system 110 can includea piping system to control fluid flow to a pool, and a second pipingsystem to control fluid flow to a spa. For this particular example, theflow requirements for the pool and the spa are generally different andmay define or require separate settings of the controller 150, 150 a forthe controller 150, 150 a to operate the motor 145 to control fluid flowto the pool, the spa, or both. The fluid-movement system 110 can includeone or more valves that may be manually or automatically operated todirect fluid flow as desired. In an exemplary case where thefluid-movement system 110 includes one solenoid valve, a user canoperate the valve to direct flow to one of the pool and the spa.Additionally, the controller 150, 150 a can include a sensor or receivercoupled to the valve to determine the position of the valve. Under theabove mentioned conditions, the controller 150, 150 a can run acalibration sequence and determine individual settings and trip valuesfor the fluid system including the pool, the spa, or both. Otherconstructions can include a different number of vessels 105, where fluidflow to the number of vessels 105 can be controller by one or morefluid-movement systems 110.

While numerous aspects of the controller 150, 150 a were discussedabove, not all of the aspects and features discussed above are requiredfor the invention. Additionally, other aspects and features can be addedto the controller 150, 150 a shown in the figures.

The constructions described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the invention. Various features andadvantages of the invention are set forth in the following claims.

1. A pumping apparatus for a jetted-fluid system comprising a vessel forholding a fluid, a drain, and a return, the pumping apparatus beingconnectable to a power source and comprising: a pump including an inletconnectable to the drain, and an outlet connectable to the return, thepump adapted to receive the fluid from the drain and jet fluid throughthe return; a motor coupled to the pump to operate the pump; a sensorconnectable to the power source and configured to generate a signalhaving a relation to a parameter of the motor; a switch coupled to themotor and configured to control at least a characteristic of the motor;and a microcontroller coupled to the sensor and the switch, themicrocontroller configured to generate a derivative value based on thesignal, and to control the motor based on the derivative value.
 2. Thepumping apparatus of claim 1, wherein the microcontroller is configuredto calculate a value indicative of the parameter, and to generate thederivative value based on the value.
 3. The pumping apparatus of claim1, wherein the sensor includes a voltage sensor configured to generate afirst signal having a relation to a voltage applied to the motor, and acurrent sensor configured to generate a second signal having a relationto a current applied to the motor, and wherein the microcontroller isconfigured to generate the derivative value based on the first signaland the second signal.
 4. The pumping apparatus of claim 1, wherein thesensor includes a voltage sensor and a current sensor, the parameterincludes a motor input power, and the derivative value includes aderivative value of the motor input power.
 5. The pumping apparatus ofclaim 4 wherein the microcontroller is configured to determine the motorinput power based on signals from the voltage and current sensors, andto determine the derivative value based on the motor input power.
 6. Thepumping apparatus of claim 1, wherein the parameter includes a motortorque, and the derivative value includes a derivative value of themotor torque.
 7. The pumping apparatus of claim 1, wherein the parameterincludes a motor power factor, and the derivative value includes aderivative value of the motor power factor.
 8. The pumping apparatus ofclaim 1, wherein the microcontroller is further configured to monitorthe derivative value, determine whether the monitored derivative valueindicates an undesired flow of fluid through the pump, and control themotor to cease operation of the pump when the determination indicates anundesired flow of fluid through the pump and zero or more otherconditions exist.
 9. A pumping apparatus for a jetted-fluid systemcomprising a vessel for holding a fluid, a drain, and a return, thepumping apparatus being connectable to a power source and comprising: apump including an inlet connectable to the drain, and an outletconnectable to the return, the pump adapted to receive the fluid fromthe drain and jet fluid through the return; a motor coupled to the pumpto operate the pump; a sensor coupled to the motor and configured togenerate a signal having a relation to a power of the motor; a switchcoupled to the motor and configured to control at least a characteristicof the motor; and a microcontroller coupled to the sensor and the relaycircuit, the microcontroller configured to generate a derivative valueof a parameter based on the signal, and to control the motor based onthe derivative value.
 10. The pumping apparatus of claim 9, wherein themicrocontroller is configured to calculate a value indicative of theparameter, and to generate the derivative value based on the value. 11.The pumping apparatus of claim 9, wherein the sensor includes a voltagesensor configured to generate a first signal having a relation to avoltage applied to the motor, and a current sensor configured togenerate a second signal having a relation to a current applied to themotor, and wherein the microcontroller is configured to generate thederivative value based on the first signal and the second signal. 12.The pumping apparatus of claim 9, wherein the sensor includes a voltagesensor and a current sensor, the parameter includes a motor input power,and the derivative value includes a derivative value of the motor inputpower.
 13. The pumping apparatus of claim 12 wherein the microcontrolleris configured to determine the motor input power based on signals fromthe voltage and current sensors, and to determine the derivative valuebased on the motor input power.
 14. The pumping apparatus of claim 9,wherein the microcontroller is further configured to monitor thederivative value, determine whether the monitored derivative valueindicates an undesired flow of fluid through the pump, and control themotor to cease operation of the pump when the determination indicates anundesired flow of fluid through the pump and zero or more otherconditions exist.
 15. A method of controlling a motor operating apumping apparatus of a fluid-pumping application, the pumping apparatuscomprising a pump having an inlet to receive a fluid and an outlet toexhaust the fluid, and the motor coupled to the pump to operate thepump, the method comprising: sensing a motor current; sensing a motorvoltage; obtaining a derivative value of the motor power based on thesensed voltage and the sensed current; determining whether thederivative value indicates a condition of the pump; and controlling themotor to operate the pump based on the condition of the pump.
 16. Themethod of claim 15, further comprising obtaining a power value of themotor power based on the sensed voltage and the sensed current.
 17. Themethod of claim 15, wherein the condition of the pump is an undesiredflow of fluid through the pump.
 18. The method of claim 15, wherein thepumping apparatus further comprises a voltage sensor and a currentsensor, wherein sensing a motor voltage comprises sensing a voltageapplied to the motor with the voltage sensor, and wherein sensing amotor current comprises sensing a current through the motor with thecurrent sensor.
 19. A pumping apparatus for a jetted-fluid systemcomprising a vessel for holding a fluid, a drain, and a return, thepumping apparatus being connectable to a power source and comprising: apump including an inlet connectable to the drain, and an outletconnectable to the return, the pump adapted to receive the fluid fromthe drain and jet fluid through the return; a motor coupled to the pumpto operate the pump; a sensor connectable to the power source andconfigured to generate a signal having a relation to a parameter of themotor; a switch coupled to the motor and configured to control at leasta characteristic of the motor; and a derivative device coupled to thesensor and the switch, the derivative device configured to generate aderivative value based on the signal to control the motor based on thederivative value.
 20. The pumping apparatus of claim 20, wherein thederivative device includes an operational amplifier circuit.
 21. Thepumping apparatus of claim 20, wherein the sensor includes a voltagesensor configured to generate a first signal having a relation to avoltage applied to the motor, and a current sensor configured togenerate a second signal having a relation to a current applied to themotor, and wherein the derivative device is configured to generate thederivative value based on the first signal and the second signal. 22.The pumping apparatus of claim 20, wherein the sensor includes a voltagesensor and a current sensor, the parameter includes a motor input power,and the derivative value includes a derivative value of the motor inputpower.
 23. The pumping apparatus of claim 20, wherein the parameterincludes a motor torque, and the derivative value includes a derivativevalue of the motor torque.
 24. The pumping apparatus of claim 20,wherein the parameter includes a motor power factor, and the derivativevalue includes a derivative value of the motor power factor.
 25. Apumping apparatus for a jetted-fluid system comprising a vessel forholding a fluid, a drain, and a return, the pumping apparatus beingconnectable to a power source and comprising: a pump comprising an inletconnectable to the drain, and an outlet connectable to the return, thepump adapted to receive the fluid from the drain and jet fluid throughthe return; a motor coupled to the pump to operate the pump; a sensorconfigured to generate a signal having a relation to a parameter of themotor; a switch coupled to the motor and configured to control acharacteristic of the motor; and a microcontroller coupled to the sensorand the switch, the microcontroller configured to generate a value basedon the signal, the value having a relation to the motor torque, and tocontrol the motor based on the value.
 26. The pumping apparatus of claim25, wherein the sensor is connectable to the power source.
 27. Thepumping apparatus of claim 25, wherein the sensor is coupled to themotor.
 28. The pumping apparatus of claim 25, wherein the sensorincludes a current sensor configured to generate a signal related to thecurrent of the motor.
 29. The pumping apparatus of claim 26, and furthercomprising a second sensor configured to generate a signal indicative ofthe speed of the motor.
 30. The pumping apparatus of claim 26, whereinthe microcontroller is further configured to determine the speed of themotor, and wherein the value has a further relation to the speed of themotor.
 31. The pumping apparatus of claim 27, wherein themicrocontroller is further configured to determine a relationshipbetween the speed of the motor and the signal related to the current ofthe motor to calculate the value.
 32. The pumping apparatus of claim 25,wherein the microcontroller is further configured to monitor the value,determine whether the monitored value indicates an undesired flow offluid through the pump, and control the motor to cease operation of thepump when the determination indicates an undesired flow of fluid throughthe pump and zero or more other conditions exist.
 33. A method ofcontrolling a motor operating a pumping apparatus of a jetted fluidsystem comprising a vessel for holding a fluid, a drain, and a return,the pumping apparatus comprising a pump having an inlet connectable tothe drain, and an outlet connectable to the return, the pump adapted toreceive the fluid from the drain and jet fluid through the return, andthe motor coupled to the pump to operate the pump, the methodcomprising: controlling the motor to operate the pump; sensing a currentof the motor; calculating a torque of the motor based on the sensedcurrent; determining whether the torque indicates a condition of thepump; and further controlling the motor to operate the pump based on thecondition of the pump.
 34. The method of claim 33, wherein monitoringthe operation of the pump further comprises sensing a voltage applied tothe motor; determining a speed value related to the motor; and whereinthe calculating a torque is further based on the speed value.
 35. Themethod of claim 33, further comprising sensing a speed of the motor; andwherein the calculating a torque is further based on the sensed speed.36. The method of claim 33, further comprising calculating a valueindicative of input power to the motor; and determining a linearrelationship between the torque and the input power to the motor.